Last Modified: 08-30-2021 6.10:8.0.50 Doc ID: RM100000001H0GX
Model Year Start: 2019 Model: Prius Prod Date Range: [12/2018 - 07/2020]
Title: HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL; 2019 - 2020 MY Prius [12/2018 - 07/2020]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during inverter with converter assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedures

Effect/Inoperative Function when Necessary Procedure not Performed

Link

*1: When performing learning using the Techstream.

Click here 2019 - 2022 MY Prius [12/2018 -        ]; PARK ASSIST / MONITORING: INTELLIGENT CLEARANCE SONAR SYSTEM: CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Memorize steering angle neutral point

Lane departure alert system (w/ Steering Control)

2016 - 2020 MY Prius [11/2015 - 07/2020]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Intelligent clearance sonar system*1

Simple advanced parking guidance system*1

Pre-collision system

AFS (Adaptive Front-lighting System)

Initialize back door lock

Power door lock control system

2016 - 2022 MY Prius [11/2015 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

Replacement of inverter with converter assembly

Resolver learning

  • DTCs are stored
  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
  • Shock or vibration during acceleration

2016 - 2022 MY Prius [11/2015 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): UTILITY for Nickel Metal Hydride Battery

2016 - 2022 MY Prius [11/2015 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): UTILITY for Lithium-ion Battery

Replacement of ECM

Perform Vehicle Identification Number (VIN) registration

MIL comes on

2016 - 2022 MY Prius [11/2015 -        ]; 2ZR-FXE (ENGINE CONTROL): SFI SYSTEM: REGISTRATION

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    for NICKEL METAL HYDRIDE BATTERY: Click here 2019 - 2020 MY Prius [12/2018 - 07/2020]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): PRECAUTION

    for LITHIUM-ION BATTERY: Click here 2019 - 2020 MY Prius [12/2018 - 07/2020]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): PRECAUTION

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here 2019 MY Prius [12/2018 - 08/2019]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION 2020 - 2022 MY Prius [08/2019 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

2. DISCONNECT ENGINE WIRE

(a) Disengage the 2 claws and disconnect the engine wire from the battery current sensor holder.

(b) Disconnect the battery state sensor assembly connector.

3. REMOVE AUXILIARY BATTERY

Click here 2019 - 2020 MY Prius [12/2018 - 07/2020]; 2ZR-FXE (BATTERY / CHARGING): AUXILIARY BATTERY: REMOVAL

4. REMOVE SERVICE PLUG GRIP

Click here 2019 - 2020 MY Prius [12/2018 - 07/2020]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

5. REMOVE REAR MOTOR UNDER COVER LH

Click here 2016 - 2022 MY Prius [11/2015 -        ]; HYBRID / BATTERY CONTROL: COOLANT(for Inverter): REPLACEMENT+

6. DRAIN COOLANT (for Inverter)

Click here 2016 - 2022 MY Prius [11/2015 -        ]; HYBRID / BATTERY CONTROL: COOLANT(for Inverter): REPLACEMENT+

7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

Click here 2019 - 2020 MY Prius [12/2018 - 07/2020]; 2ZR-FXE (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here 2016 - 2022 MY Prius [11/2015 -        ]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL

9. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click here 2019 - 2022 MY Prius [12/2018 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER: REMOVAL+

10. REMOVE WATER GUARD PLATE LH

Click here 2019 - 2022 MY Prius [12/2018 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER: REMOVAL+

11. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

Click here 2019 - 2022 MY Prius [12/2018 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER: REMOVAL+

12. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here 2019 - 2022 MY Prius [12/2018 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER: REMOVAL+

13. REMOVE ECM

Click here 2019 - 2020 MY Prius [12/2018 - 07/2020]; 2ZR-FXE (ENGINE CONTROL): ECM: REMOVAL

14. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Remove the 3 bolts and battery clamp sub-assembly.

15. DISCONNECT ENGINE WIRE

CAUTION:

Wear insulated gloves.

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

(a) Remove the No. 1 relay block cover.

(b) Disconnect the 3 No. 1 engine room relay block and No. 1 junction block assembly connectors.

(c) Disengage the 2 claws.

(d) Move each lock lever as shown in the illustration and disconnect the 2 inverter with converter assembly connectors.

NOTICE:

  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Insulate the disconnected terminals with insulating tape.
  • Do not touch the waterproof seal or terminals of the connector.

(e) Remove the bolt.

(f) Disengage the clamp (A) and remove the inverter protector.

(g) Disengage the clamp (B).

(h) Remove the bolt.

(i) Disengage the 2 clamps and disconnect the engine wire.

16. REMOVE CONNECTOR COVER ASSEMBLY

CAUTION:

Wear insulated gloves.

(a) Remove the bolt (B).

*a

Bolt (A)

*b

Bolt (B)

(b) Using a T25 "TORX" socket wrench, remove the bolt (A) and connector cover assembly from the inverter with converter assembly.

NOTICE:

  • Do not touch the connector cover assembly waterproof seal.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.

17. CHECK TERMINAL VOLTAGE

CAUTION:

Wear insulated gloves.

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

(a) Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

Standard Voltage:

0 V

HINT:

Use a measuring range of DC 750 V or more on the voltmeter.

18. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:

Wear insulated gloves.

(a) Temporarily install the connector cover assembly to the inverter with converter assembly.

(b) Using a T25 "TORX" socket wrench, install the bolt.

Torque:

4.5 N·m {46 kgf·cm, 40 in·lbf}

NOTICE:

Do not touch the waterproof seal of the connector cover assembly.

19. DISCONNECT HV FLOOR UNDER WIRE

CAUTION:

Wear insulated gloves.

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

(a) Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.

NOTICE:

  • Do not touch the waterproof seal or terminals of the connector.
  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Insulate the disconnected terminals with insulating tape.

*a

Waterproof Seal

(b) Disengage the 2 clamps.

20. DISCONNECT AIR CONDITIONING WIRE

CAUTION:

Wear insulated gloves.

(a) Remove the 2 bolts and disconnect the air conditioning wire from the inverter with converter assembly.

NOTICE:

  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Do not touch the waterproof seal or terminals of the connector.
  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Insulate the disconnected terminals with insulating tape.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

*a

Waterproof Seal

(b) Disengage the clamp.

21. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the nut and wire harness clamp bracket.

22. DISCONNECT NO. 3 ENGINE WIRE

CAUTION:

Wear insulated gloves.

(a) Remove the bolt.

(b) Remove the bolt.

(c) Disengage the 2 claws and open the No. 3 engine wire terminal cover.

(d) Remove the nut.

(e) Disengage the clamp and disconnect the No. 3 engine wire from the inverter with converter assembly.

23. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the outlet No. 1 inverter cooling hose from the inverter with converter assembly.

NOTICE:

Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

24. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the inlet No. 1 inverter cooling hose from the inverter with converter assembly.

NOTICE:

Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

25. REMOVE INVERTER COVER

CAUTION:

Wear insulated gloves.

(a) Remove the 2 bolts and inverter cover from the inverter with converter assembly.

NOTICE:

  • Make sure to pull the inverter cover straight out, as a connector is connected to the inside of the inverter cover.
  • Do not touch the waterproof seal of the inverter cover.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • When removing the inverter cover, do not pull the areas (A) as they may deform.
  • Make sure that the interlock is installed to the inverter cover.
  • Do not remove or excessively tighten the screw of the inverter cover.

    *1

    Inverter Cover

    *a

    Screw

  • Although the inverter cover may feel loose, this is not due to a malfunction.

HINT:

If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the inverter cover.

*a

Interlock

*b

Waterproof Seal

26. DISCONNECT MOTOR CABLE

CAUTION:

Wear insulated gloves.

(a) Using an insulated tool, remove the 6 bolts.

NOTICE:

  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Do not touch the waterproof seal or terminals of the connector.

(b) Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.

*a

Waterproof Seal

NOTICE:

  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Do not touch the waterproof seal or terminals of the connector.
  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Insulate the disconnected terminals with insulating tape.
  • After disconnecting the motor cable, wrap it with a plastic bag or equivalent to protect it.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

27. REMOVE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Wear insulated gloves.

(a) Remove the 5 bolts, 2 nuts and inverter with converter assembly.

NOTICE:

  • When removing the inverter with converter assembly, be careful not to damage the parts around it.
  • To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or cooling pipes.
  • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

HINT:

Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly so that coolant does not spill out.

28. REMOVE NO. 1 INVERTER BRACKET

(a) Set the inverter with converter assembly on wooden blocks.

*a

Wooden Block

NOTICE:

Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

(b) Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.

29. REMOVE NO. 2 INVERTER BRACKET

(a) Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.

*a

Wooden Block

30. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the 2 bolts and 2 wire harness clamp brackets from the inverter with converter assembly.

(b) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

(c) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.